Hi-flow variable speed pump with wireless remote control

ABSTRACT

A high-capacity pump fabricated with improved motor cooling and corrosion resistant components and powered by a variable-speed brushless DC motor suitable for use with a wide variety of applications. A brushless 12V DC motor is controlled by a manual and wireless variable speed control means to provide unparalleled flow control. The motor is contained within the housing in a sealed cavity in the housing, wherein the cavity is filled with mineral oil which maximizes heat transfer to facilitate motor cooling. A PVC impeller is contained within a PVC section of the housing thereby creating a corrosion resistant impeller section. The pump of the present invention has achieved improved performance over known pumps and is capable of delivering 4,500 gallons per hour (GPH) at 6 feet of head pressure, while only drawing 30 amps at 12 Volts DC. Wireless remote control of the pump is achieved via a wireless enabled device.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/342,278, filed on Nov. 3, 2016, now U.S. Pat. No. 10,267,316, whichclaims the benefit of provisional U.S. Patent Application Ser. No.62/250,169, filed on Nov. 3, 2015.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

N/A

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor patent disclosure as it appears in the Patent and Trademark Officepatent file or records, but otherwise reserves all rights whatsoever.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to pump systems, and more particularly toa variable-speed, high-capacity pump system for circulating water for avariety of applications, including marine bait well circulation andprocess water circulation.

2. Description of Related Art

Marine vessels use pumps to circulate water for a number of applicationsincluding baitwell circulation, process water circulation, and potablewater supply. Baitwells, live wells, and bait tanks are among the morecommonly used terms to describe water tank systems installed on marinevessels for temporary storage of live marine life, such as bait fish.These systems typically including a tank or well, which come in varioussizes (e.g. gallon capacities), and which may include a variety ofoptions such as pumps and aerators. The systems may be configured as:(1) an “open system” wherein new oxygen rich water is continually pumpedinto the tank while old water flows out and back to sea; or (2) a“closed system” wherein the water is merely recirculated. A constantflow of water provides the fish with necessary oxygen to prevent oxygenstarvation to ensure survival. Maintaining proper water flow isimportant, as insufficient flow can lead to impurities to build-up,whereas too much flow can cause turbulence causing the bait fish to diefrom exhaustion or scale loss. As a result, baitwell pumps limited tonon-variable constant flow output suffer from a significant limitation.

Baitwell pumps typically run for many hours at a time in harsh marineenvironments. As a result of hard use in extreme environments,conventional baitwell pumps have been known to suffer from reliabilityissues. A number of baitwell pump failures have been attributed to thepump drawing in air causing “air locks” which effect pump cooling andare known to cause pump failure due to overheating. In order to addressthis issue, a number of boat owners are forced to install a sea chest,which comprises a watertight box which is filled with water in order tomaintain the baitwell pump(s) installed therein fully submerged.Installing sea chests, however, is expensive, adds weight to the vessel,and requires space which is in short supply.

As noted above, marine vessels employ pumps for a number of otherapplications including process applications, such as condenser watercirculation for onboard air conditioning systems, as well as pumps forfreshwater applications. In air conditioning applications, the pumpstypically circulate seawater through a condenser coil in order to removeheat from the system and condense refrigerant. In other applications,marine pumps may be installed to pressurize fresh potable water for usein kitchens, wet bars, showers, and bathrooms. Regardless of theinstallation, pumps installed on marine vessels are subject to harshmarine environments, and have exhibited premature failures resultingfrom corrosion and other environmental factors. More particularly, anumber of marine vessel pumps are fabricated using conventional brushedmotor technology, and other components fabricated from materials thatare susceptible to corrosion. As a result of these factors, marine pumpsare known to exhibit premature failures.

BRIEF SUMMARY OF THE INVENTION

The present invention overcomes the limitations and disadvantagespresent with baitwell systems present in the art by providing ahigh-capacity pump fabricated with corrosion resistant components, andpowered by a variable-speed brushless DC motor suitable for use with awide variety of baitwell applications. A pump in accordance with thepresent invention includes a corrosion resistant compact housingfabricated from aircraft grade 5086 and 6061 Aluminum, Titanium, andDELRIN® (e.g. Polyoxymethylene). DELRIN® is a registered trademark of E.I. DuPont de Nemours and Company. The housing includes a motor andelectronics section fabricated primarily from Aluminum, and an impellersection formed primarily from DELRIN®. The housing contains a brushless12V DC motor which is controlled by a manual and wireless variable speedcontrol to provide unparalleled flow control. The motor is containedwithin the housing in a sealed cavity in the housing, wherein the cavityis filled with mineral oil which maximizes heat transfer to facilitatemotor cooling. A PVC impeller is contained within a PVC section of thehousing thereby creating a corrosion resistant housing and impellersection. The pump of the present invention has achieved improvedperformance over known pumps, and is capable of delivering 4,500 gallonsper hour (GPH) at 6 feet of head pressure, while only drawing 30 amps at12 Volts DC.

Pump output is controllable between minimum and maximum flowrates byadjusting motor speed. The present invention provides two independentmotor control systems, including a manual speed control knob or dial,and via a wireless electronic device such as a smartphone using adownloadable software application or App that allows for remote controlof the pump. Providing wireless control is considered an importantaspect of the present invention as it allows for remote activation andcontrol of the pump from anywhere on the vessel.

Accordingly, it is an object of the present invention to provide animproved pump for marine applications.

Another object of the present invention is to provide a variable speedpump powered by a brushless DC motor.

Still another object of the present invention is to provide an improvedpump fabricated from corrosion resistant materials.

Yet another object of the present invention is to provide a variablespeed pump with improved motor cooling.

In accordance with these and other objects, which will become apparenthereinafter, the instant invention will now be described with particularreference to the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a side view of a pump in accordance with the present inventionwith the pump disposed in a horizontal configuration;

FIG. 2 is a side view of the pump disposed in a vertical configuration;

FIG. 3 is a schematic side sectional view of the pump;

FIG. 4 is a schematic block diagram of the motor control architecture;

FIG. 5 illustrates a wiring schematic for the pump system using a single12V battery;

FIG. 6 illustrates a wiring schematic for the pump using two 12Vbatteries wired in series; and

FIG. 7 illustrates a solenoid wiring schematic for the pump.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be understood more readily by reference to thefollowing detailed description taken in connection with the accompanyingdrawing figures, which form a part of this disclosure. It is to beunderstood that this invention is not limited to the specific devices,methods, conditions or parameters described and/or shown herein, andthat the terminology used herein is for the purpose of describingparticular embodiments by way of example only and is not intended to belimiting of the claimed invention. Any and all patents and otherpublications identified in this specification are incorporated byreference as though fully set forth herein.

Also, as used in the specification including the appended claims, thesingular forms “a,” “an,” and “the” include the plural, and reference toa particular numerical value includes at least that particular value,unless the context clearly dictates otherwise. Ranges may be expressedherein as from “about” or “approximately” one particular value and/or to“about” or “approximately” another particular value. When such a rangeis expressed, another embodiment includes from the one particular valueand/or to the other particular value. Similarly, when values areexpressed as approximations, by use of the antecedent “about,” it willbe understood that the particular value forms another embodiment.

Turning now to the drawings, FIGS. 1-3 depict a pump, generallyreferenced as 10, in accordance with the present invention, FIG. 4depicts a block diagram of the motor control architecture, and FIGS. 5-7depict wiring schematics for use of the pump in marine baitwell pumpapplications. As noted above, pump 10 is suitable for a variety ofmarine vessel pumping applications as well as non-marine general usepumping applications. Accordingly, any reference to baitwellapplications should not be construed as limiting.

With reference to FIGS. 1-3, pump 10 includes a housing assembly,generally to referenced as 12, including an impeller housing 14 and amotor/electronics housing assembly, generally referenced as 16. Housing14 and housing assembly 16 are connected so as to form a watertightseal. Impeller housing 14 is fabricated from a non-corrosive material,preferably polyvinyl chloride (“PVC”), and contains an impeller 15, asseen in FIG. 3, which is fabricated from DELRIN®. An important aspect ofthe present invention involves fabricating impeller housing 14 as wellas impeller 15 from a non-corrosive material, such as PVC and DELRIN®.Fabricating those components from lightweight and corrosion resistantmaterials renders the pump highly corrosion resistant. Housing 14further includes a water inlet 18 and a water outlet 20. Water inlet 18is generally axially disposed at the end of impeller housing 14 asillustrated in FIGS. 1 and 2. Water outlet 20 is generallyperpendicularly disposed relative to inlet 18 and generally tangentialrelative to impeller housing 14 as seen in FIGS. 1 and 2. Water inlet 18is formed by a cylindrical axially projecting pipe connection, whichpreferably defines a national pipe thread taper (“NPT”) of 1.5″ or 2.0″,however any suitable size or threaded or non-threaded configuration isconsidered within the scope of the present invention. Water outlet 20 isformed by a cylindrical tangentially projecting pipe connection, whichpreferably defines a NPT outlet of preferably 1.25″ or 1.5″, or anyother suitable outlet size or configuration. As should be apparent,during operation water is drawn into inlet 18 and discharged from outlet20.

Motor/electronics housing assembly 16 is formed by three components,namely a motor housing component 16A, an electronics housing component16B, and an end cap 16C, each of which is connected in asealed/watertight manner. In an alternate embodiment, however,motor/electronics housing assembly may comprise a single mainmotor/electronics housing and end cap. Motor housing component 16A is insealed threaded engagement with impeller housing 14 via an O-ring gasketor seal, referenced as 23. Motor housing 16A defines a motor receivingcavity 17 wherein an electric motor 30 is received and/or partiallyreceived. Electric motor 30 is preferably a 12 V DC powered brushlessmotor. Use of a brushless motor increases reliability by eliminating theuse of brushes in conventional electric motors. Motor 30 has an outputshaft 31 which projects from motor 30 through a bearing 33 and fromhousing 16A through a watertight seal 19. The terminal end of outputshaft 31 is connected to impeller 15. Shaft 31 is preferably fabricatedfrom a highly corrosion-resistant material, such as 316 stainless steel.

A significant aspect of the present invention involves enhanced motorcooling to prevent overheating, a known cause of failure for prior artsystems. In accordance with this aspect of the invention, the areasurrounding motor 30 within cavity 17 is substantially, but not fully,filled with mineral oil 29 which functions to lubricate, protect, andprimarily cool motor 30. As used herein the term “mineral oil” shall bebroadly construed to mean a distillation product of petroleum, or anyother suitable non-conductive, non-corrosive, liquid. Partially fillingcavity 17 allows for an air-gap (shown as blank space depicted above themineral oil) that functions to accommodate thermal expansion of mineraloil 29. Surrounding motor 30 with a fluid, such as mineral oil, improvesheat transfer from the motor due to the increased coefficient of heattransfer of the oil, as opposed to gas such as air. Accordingly, heat isreadily transferred from the motor to the oil during operation. Afurther significant aspect of the present invention involves use of thepumped water to extract and discharge the heat. In this regard, aportion of the exterior of motor 16A, referenced as 16A′ projects intoimpeller housing 14, and is in direct fluid contact with water flowingthrough impeller housing 14 as best seen in FIG. 3. Accordingly, heattransferred from motor 30 and to the mineral oil 29 disposed withincavity 17 is subsequently transferred from the mineral oil, through thewall of motor housing 16A, and into water within impeller housing 14,whereby the heat is extracted from the pump by discharge of the waterfrom outlet 20. It is important to note that cavity 17 is only partiallyfilled with mineral oil so as to leave a quantity of air therein,whereby the air allows for thermal expansion of the mineral oil inresponse to temperature increases thereby preventing excess pressurebuild-up on any seals or gaskets.

Electronics housing component 16B is preferably in sealing threadedengagement with motor hosing component 16A via an O-ring seal 13.Electronics housing component 16B defines a cavity 21 that contains, ina watertight environment, the electronic components used to power andcontrol motor 30. A multi-conductor cable 34 brings 12V DC power andcontrol signals into electronics housing component 16B via a watertightport 35 formed in end cap 16C. Power may be provided to microprocessor42 and motor speed controller 44 in parallel or series or any othersuitable electrical configuration. Included in cable 34 are conductorsdedicated to electrically communicating variable speed control inputsignals from the manually adjustable speed control potentiometer 40(illustrated in FIGS. 4 and 7) to microprocessor 42 via watertight wireconnector 35 disposed in an aperture formed in housing component 16C.The speed control cable is preferably combined with power cable 34 inthe form of a multi-conductor cable, however any suitable conductorconfiguration is considered within the scope of the present invention.Electronics housing component 16B also preferably contains mineral oil29 which comprises a non-conductive liquid. Mineral oil functions toremove heat from the enclosed electronic components. More particularly,the heat generated within electronics housing component 16B istransferred to the motor housing component by conduction, and ultimatelyinto the water flowing through the impeller housing whereby the heat isremoved from the system. It is important to note that cavities 21 and 17are only partially filled with mineral oil so as to leave a quantity ofair therein which allows for thermal expansion of the mineral oil inresponse to temperature increases thereby maintaining the integrity ofthe various seals. A cap 16C is disposed in threaded engagement withhousing component 16B, wherein an O-ring seal or gasket 13 maintainssealed engagement.

FIG. 4 is an electrical control block diagram for the electrical controlsystem for the baitwell pump 10 in accordance with the presentinvention. The electrical control system includes a speed controlpotentiometer 40 which functions to allow for speed variation via directuser input by manual actuation of speed control knob (shown in FIG. 6).Speed control potentiometer 40 functions to provide a speed controlsignal to a microprocessor 42, which is in electrical communication witha motor speed controller 44. Microprocessor 42 receives the speedcontrol signal and generates an output signal to motor speed controller44 which uses that signal to controls the input voltage to motor 30.Using this control architecture, rotation of the control knob on speedcontrol potentiometer 40 functions to vary motor speed resulting in acorresponding variance in water flow output. A 12V DC power source 46 iselectrically connected to motor speed controller 44, and microprocessor42 receives power therefrom. The 12 V DC power may be obtained directlyfrom a 12V DC battery or from a pair of 12V DC batteries providing 24VDC to a converter as illustrated in FIG. 6.

A further significant aspect of the present invention involves theability to control the pump via wireless communication. In accordancewith this aspect of the invention, pump 10 is provided with a wirelesstransceiver 48 adapted to for exchanging data over short distances. In apreferred embodiment, wireless transceiver uses short-wavelength UHFradio waves in the ISM band from 2.4 to 2.485 GHz from fixed and mobiledevices in accordance with the BLUETOOTH® standard. BLUETOOTH® is aregistered trademark of Bluetooth SIG, Inc. of Kirdland Washington.While BLUETOOTH® is disclosed as the wireless transmission protocol in afirst embodiment, the present inventor, however, contemplates the use ofany suitable wireless communication protocol or standard.

In addition, a downloadable software application or APP 50 is providedfor downloadable installation via the Internet 52 on a wireless enabledportable electronic device 54. Wireless electronic device 54 preferablycomprises a smartphone. Once installed on electronic device 54, APP 50provides for the wireless control of pump 10. More particularly, APP 50generates a graphical user interface (“GUI”) on device 54 which allowsthe user to send commands to and receive data from pump 10. APP 50 thusallows a user to remotely turn pump 10 “On” and “Off” while furtherallowing the user to make adjustments to pump flow between minimum andmaximum settings. APP 50 further receives data from motor 10 viatransceiver 48 and generates electronic output displays such that theuser can monitor pump status, flow rates, etc.

FIG. 5 illustrates a wiring diagram for installation of pump 10 of thepresent invention in a baitwell application using a single 12V DCbattery, referenced as 100. An on/off switch 102 is wired to a solenoid104, whereby manual actuation of switch 102 (e.g. to the “on” position”)activates solenoid 104 to provide 12V DC power to baitwell pump 10. FIG.6 illustrates a wiring diagram for installation of a baitwell pump 10 ofthe present invention in an application wherein two 12 VDC batteries arewired in series thereby providing a 24V DC potential. In thisapplication an on/off switch 102 is wired to a solenoid 104 such thatmanual activation of switch 102 to the on position activates solenoid104. Upon activation of solenoid 104, 24V DC power is provided to avoltage converter 106, which reduces the voltage to 12 V DC. Asillustrated voltage converter 106 in turn is electrically connected tobaitwell pump so as to provide 12V DC operating voltage thereto. FIG. 7provides a detailed illustration of the wiring of solenoid 104.

The present invention thus overcomes the limitations and disadvantagespresent with baitwell systems present in the art by providing ahigh-capacity pump fabricated with corrosion resistant components andpowered by a variable-speed brushless DC motor suitable for use inbaitwell applications as well as with a wide variety of other marinevessel applications. The pump of the present invention has achievedimproved performance over known pumps and is capable of delivering 4,500gallons per hour (GPH) at 6 feet of head pressure, while only drawing 30amps at 12 V DC.

The instant invention has been shown and described herein in what isconsidered to be the most practical and preferred embodiment. It isrecognized, however, that departures may be made therefrom within thescope of the invention and that obvious modifications will occur to aperson skilled in the art.

What is claimed is:
 1. An electric pump comprising: an impeller housing,said impeller housing defining an interior volume and having a waterinlet and a water outlet, said impeller housing formed of anon-corrosive synthetic plastic polymer; an impeller disposed within theinterior volume of said impeller housing, said impeller formed of anon-corrosive synthetic material; a second housing assembly connected insealing engagement to said impeller housing, said second housingassembly defining at least one cavity therein, said second housingassembly including a portion thereof projecting into the interior volumeof said impeller housing, whereby water flowing through said impellerhousing absorbs and carries away heat generated within said secondhousing assembly; a brushless DC electric motor disposed within saidsecond housing, said brushless DC electric motor having an output shaftprojecting from said second housing through a watertight seal and intosaid impeller housing, said output shaft connected to said impeller; amicroprocessor and a motor speed controller disposed within said secondhousing assembly, said microprocessor in electric communication withsaid motor speed controller; an external 12 VDC power source in electriccommunication with each of said microprocessor and said motor speedcontroller; said motor speed controller in electrical communication withsaid brushless DC electric motor; and a motor speed controlpotentiometer located remote from said electric pump and in electricalcommunication with said microprocessor, whereby motor speed controlsignals from said motor speed control potentiometer are received by saidmicroprocessor which generates an output signal to said motor speedcontroller which varies the input voltage to said brushless DC electricmotor in response to said output signal.
 2. The electric pump accordingto claim 1, wherein the at least one cavity of said second housingassembly is partially filled with mineral oil.
 3. The electric pumpaccording to claim 1, wherein said non-corrosive synthetic materialcomprises polyoxymethylene.
 4. The electric pump according to claim 1,wherein said output shaft is formed from stainless steel.
 5. Theelectric pump according to claim 1, wherein said second housing assemblyis formed from Aluminum.
 6. The electric pump according to claim 1further including a wireless transceiver in electronic communicationwith said microprocessor and a wireless communications device configuredfor wireless communication with said wireless transceiver, said wirelesscommunications device adapted to transmit wireless motor control signalsto said wireless transceiver, whereby said wireless motor controlsignals are relayed to said microprocessor by said wireless transceiverto effectuate motor speed control.